Process of weaving pile fabrics



Sept. 21, 1943. J, BAKER 2,329,738

PROCESS OF WEAVING FILE FABRICS Filed April 21, 1942 Patented Sept. 21, 1943 UNITED STATES PATENT OFFICE- 2,329,738 PROCESS 'OF WEAVING PILE FABRICS Joseph L. Baker, Langhorne Manor, Pa.

Application April 21, 1942, Serial No. 439,831

2 Claims.

My invention relates to the weaving of pile fabrics and comprises a novel process for making a double pile fabric of such a character that, if out in a plane parallel to, and intermediate of, the planes of the two fabrics, it will produce two pile fabrics of a conventional type.

The double fabric produced by this process is composed of two single fabrics each containing two 'sets of binder warps, a set of stuffer warps and pairs of filler wefts, the two single fabrics being united by. a set of pile warps common to both fabrics in the manner hereinafter described.

The specific construction of the fabric will be more clearly understood by reference to Figs. 1 and 2, while the mode of manipulating the warp and weft to produce the fabric will be hereinafter described with especial reference to Figs. 3-6.

Fig. 1 is a diagram, along the line of the warp, of a fabric produced by my improved process.

Fig. 2 is a diagram of the fabric along the line of the weft.

Figs. 3, 4, 5 and 6 are diagrams, along the line of the warp, illustrating the successive arrangement of warp sheds in weaving a repeat of the fabric.

At one side of the loom is a supply (not shown) of weft or filler yarn. On the other side of the loom is a supply (not shown) of weft or filler yarn. I

As may be seen by reference to Figs. 3-6, two warp sheds-an upper shed and a lower shedare formed. Binder warps a and b and stuifer warps e are comprised in the upper shed. Binder warps c and d and stuifer warps f are comprised in the lower shed.

Each of the two shuttles m and n is of the type that does not carry its own yarn supply but is adapted, after each traverse of the warp shed, to engage the supply of weft yarn (say a) at one side of the loom and pull a double pick thereof across the loom and then release the yarn, and then to engage the supply of weft yarn (say It) on the other side of the loom and, traveling in the reverse direction, pull a double pick thereof across the loom and then release the yarn. These shuttles are actuated in any known manner, as,

for example, by picker sticks. Each shuttle in its travel in one direction traverses the upper warp shed, and in its travel in the opposite direction traverses the lower warp shed. The two shuttles travel simultaneously in opposite directions. Thus both shuttles travel always in a clockwise (or counter-clockwise) direction.

Referring first to Fig. 3, assume that the sheds are formed as shown therein: shuttle m, in its movement from left to right, has engaged the supply of weft yarn at the left side of the loom and has pulled a double pick thereof across the loom from left to right at the higher level in the shed below stuffer warps e and pile warps i and above binder warps b and has thereby inserted in the shed thus formed a pair of wefts g g of the upper fabric. Concurrently with the above operation shuttle n has engaged the supply of yarn at the right side of the m and has pulled the same across the loom from right to left at the lower level below stufier warp f and above binder warps d and has thereby inserted in the shed thus formed a pair of wefts h h of the lower fabric.

Without changing the binder warp sheds the pile warps i are now shifted from the upper shed to the lower shed, as shown in Fig. 4. Shuttle m, which is now at the right side of the loom and has released yarn g and has dropped to the lower level, now engages the supply of yarn at the right side of the loom and pulls a double pick thereof across the loom from right to left at the lower level in the shed formed above stuffer warps f and pile warps i and below binder warps c to thereby insert in the shed thus formed a pair of w fts h, h of the lower fabric. Concurrently th the above operation shuttle n, which is at the left side of the loom and has been raised to the upper level, now engages the supply of yarn at the left side of the loom and pulls a double pick thereof across the loom from left to right at the upper level in the shed formed above stuifer warp e and below binder warps a to thereby insert in the shed thus formed a pair of wefts g g of the upper fabric.

The binder warps of each shed are now reversed and the pile warps are transferred to the upper shed, as shown in Fig. 5. The shuttles are now operated in the way described in referring to Fig. 3. Without changing the binder warp sheds the pile warps are transferred to the lower shed, as shown in Fig. 6. The shuttles are now operated in the way described in referring to Fig. 4.

The above description applies to the weaving of a single repeat of the fabric. After each quarter repeat is formed, the weave is beaten into the previously woven double fabric 0 shown in Figs. 3-6.

The process described thus produces a double pile fabric, each fabric having binder warp threads, stufier warp threads and weft or filler yarns that are independent of the binder warp threads, stufier warp threads and weft or filler yarns of the other fabric, but having common pile warp threads uniting the two otherwise independent fabrics. A x

As the woven double fabric is fed intermittently forward the connecting pile yarn is severed by a cutter and the two separate fabrics are pulled around spike rolls.

A loom adapted to weave the above described double fabric is described and claimed in a Patent No. 2,285,793, issued to me June 9, 1942. on an application filed May 21, 1941, Ser. No. 394,409. Disclosure of mechanism to effect the herein described operation is, however, unnecessary, since the process is not dependent for its execution upon any particular mechanism. Indeed, aside from the necessity, from a practical commercial standpoint, of providing a power loom adapted to practice the process, its operation is not dependent upon any particular mechanism. For example, the fabric may be woven on a handoperated loom.

I have described no means for securing together the weft yarn at each longitudinal edge of the fabric 0, since this can be effected by any means known in the art. In m said patent one preferable way is shown and described, namely, a selvedge yarn shuttle one at each side of the loom which is movable through the loop of double picks of weft and is controlled in its operation by means actuated by the weft shuttles.

It will be understood that the stufier warps need not each consist of a single thread in each dent of the reed. Two or more threads may be fed from the same beam for the same dent.

While only one pile warp yarn is described it will be understood that, in the weaving of multicolored fabrics, two or more different pile warp yarns may be utilized, one being substituted for another when a. change in color is to be made. When not required on the face of the fabric, any one of these additional pile ends will be carried as dead threads of yarn in the body of either single fabric, acting like additional stuffer threads. Therefore, in claiming a set of pile warp threads I mean to include any set of such pile warp threads that may be substituted therefor. It will also be understood that such substituted pile threads may be sufiicient in number and so distributed as to dispense with the necessity of providing threads which function exclusively as stuifer threads.

As above suggested, while the pile warp threads may be all white or of natural color, some or all of them may be colored, or the yarns may be printed in such a way as to show a pattern when woven.

While the specific operation above described involves the use of double-ended shuttles of the character described, adapted to insert a double shot of weft at each traverse of the loom, it is possible to substitute for these shuttles other devices such as those known'in the art as needles, which have yam-engaging means at only one end. With the use of needles, however, a double pick of yarn can be inserted only at alternate traverses of a needle across the loom. If, therefore, only two needles were used, the advantages of this process, so far as speed of operation i concerned, would not be realized.

What I claim and desire to protect by Letters Patent is: v

l. The herein described process of weaving a repeat of a double pile fabric the two components of which comprise two fabrics connected by pile warp threads common to both fabrics, which comprise manipulating four sets of binder warp threads, two sets of stufierwarp threads and pile warp threads to formupper and lower sheds, each comprising two sets of binder warp'threads and a set of stuifer warp threads and one of the sheds containing also pile warp threads; providing a plurality of weft yarn supplies at opposite sides of the loom; drawing a double pick of weft yarn from one yarn supply entirely through the first shed between one set of binder warp threads and thestufrerwarpthreadsofthatshedandthen releasing the weft yarn and simultaneously drawing a double pick of weft yarn from another yarn supply entirely through the other shed between one set of binder warp threads of that shed and said pile warp threads and then releasing the weft yarn; then transferring said pile warp thread to the first shed; then drawing a double pick of weft yarn from one yarn supply entirely through the first shed between one set of binder warp threads of that shed and said pile warp threads and then releasing the weft yarn and simultaneously drawing a double pick of weft yarn.- from another yam supply entirely through the second shed between one set of binder warp threads and the stuffer warp threads of that shed and then releasing the weft yarn; then reversing the two sets of binder warp threads of each shed and transferring said pile warp threads to the second shed; then drawing a double pick of weft yarn from one yarn supply entirely through the first shed between one set of binder warp threads and the stufier warp threads of that shed and then releasing the weft yarn and simultaneously drawing a double pick of weft yarn from another yarn supply entirely through the other shed between one set of binder warp threads of that shed and said pile warp threads and then releasing the weft yarn; then transferring said pile warp threads to the first shed and drawing a double pick of weft yam from one yarn supply entirely through the first shed between one set of binder warp threads of that shed and said pile warp threads and then releasing the weft yarn and simultaneously drawing a double pick of weft yarn from another yarn supply entirely through the second shed between one set of binder warp threads and the stufier warp threads of that shed and then releasing the yarn.

2. The herein described process of weaving a repeat of a double pile fabric the two components of which comprise two fabrics connected by pile warp threads common to both fabrics, which comprises manipulating four set of binder warp threads, two sets of stuffer warp threads and pile warp threads to form upper and lower sheds, each comprising two sets of binder warp threads and a set of stuifer warp threads and one of the sheds containing also pile warp threads; providing two weft yarn supplia, one at each side of the loom; drawing in one direction a double pick of weft yarn from one yarn supply entirely through the first shed between one set of hinder warp threads and the stuifer warp threads of that shed and then releasing the weft yarn and simultaneously drawing in the opposite direction a double pick of weft yarn from the other yarn supply entirely through the other shed between one set of binder warp threads of that shed and said pile warp threads and then releasing the weft yarn; then transferring the pile warp threads to the first shed; then drawing in one direction a double pick of weft yarn from the first yarn supply entirely through the first shed between one set of binder warp threads of that shed and said pile warp threads and then releasing the weft yarn and simultaneously drawing in the opposite direction a double pick of weft yarn from the second yarn supply entirely through the second shed between one set of binder warp threads and the stuffer warp threads of that shed and then releasing the weft yarn; then reversing the two sets of binder warp threads of each shed and transferring said pile warp threads to the second shed; then drawing in one direction a double pick of weft yarn from the first yam supply entirely through the first shed between one set of binder warp threads and the stufler warp threads of that shed and then releasing the weft yarn and simultaneously drawing in the opposite direction a double pick of weft yam from the second yarn supply entirely through the other shed between one set of binder warp threads of that shed and said pile warp threads and then releasing the weft yam; then transferring said pile warp threads to the first shed and drawing in one direction a double pick of weft yarn from the first yam supply entirely through the first shed between one set of binder warp threads of that shed and said pile warp threads and then releasing the weft yarn and simultaneously drawing in the opposite direction a double pick or weft yarn from the second yam supply entirely through the second shed between one set of binder warp threads and the stufler warp threads of that shed and then releasing the yarn.

JOSEPH L. BAKER. 

